Apparatus and method for producing a personalized 3D object

ABSTRACT

The present invention relates to method and apparatus for producing a personalized 3D object. The method comprises steps of detecting whether a payment has been received, inviting a user to select parameters by means of a user input device and a display, capturing at least two images of a subject, calculating a 3D image with the images captured, producing and delivering the personalized 3D object to the user. In addition, a receipt comprising a web site address, a password and a set of instructions for ordering additional products are delivered to the user and the 3D image and data are transferred to a server via a network connection. The apparatus, or kiosk, comprises a payment detector, a user input device and a display, an image acquisition system, calculators for calculating a 3D image, a manufacturing device and an exit for delivering the personalized 3D object to the user.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) from provisional application No. 60/646,987 filed Jan. 27, 2005, which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to method and apparatus to produce a personalized 3D object, such as photo vending machines hereafter named photo kiosks.

BACKGROUND OF THE INVENTION

Photo kiosks were invented in 1925 by a Siberian named Anatol Josepho. These machines could take affordable portraits anonymously and automatically.

The popularity of photo kiosks has been uneven throughout the past eighty years. In their first 20 years, photo kiosks have had an explosive growth due largely to World War II, as soldiers and loved ones exchanged pictures. Later on, with the advent of the Polaroid and personal cameras, photo kiosks became less popular.

Today, with the coming of digital photography, new possibilities are offered to customers who can apply effects and make several types of modifications to pictures before printing them not only on photo paper, but on several different mediums such as, for example, photo stickers. Customers are thus regaining interest in photo kiosks.

Some attempts were made in the past to sell personalized 3D images in crystals using 3D sub surface laser engraving (SSLE) application technology. As a matter of fact, these attempts have had limited success because the early attempts were not profitable. Several limitations to profitability were encountered such as high initial investment, high operations costs because of the need to have a salesperson. For SSLE shop owners, there was no other alternative than to increase the price of each crystal unit to cover the expenses. Higher prices turned customers off the products, as the majority of them are not willing to pay premium prices even thought they are interested in the product. Thus, there is a need for a way to produce a personalized 3D object and deliver it to a customer without the aid of a salesperson.

SUMMARY OF CERTAIN INVENTIVE ASPECTS

One aspect of the present invention provides a method that satisfies the above-mentioned need.

Another aspect of the present invention iprovides a method for producing a personalized 3D object, comprising steps of:

-   -   detecting whether a payment has been received, and if a payment         is received:     -   i) inviting a user to select parameters within a bank of         parameters by means of a user input device and a display;     -   ii) capturing at least two images of a subject in view of the         parameters selected in step i);     -   iii) calculating a 3D image with said at least two images         captured in step ii);     -   iv) extracting a set of 3D data from the 3D image;     -   v) producing the personalized 3D object in view of the set of 3D         data extracted in step iv) and the parameters selected in step         i); and     -   vi) delivering the personalized 3D object to the user.

Another aspect of the present invention provides an apparatus for producing a personalized 3D object, comprising:

-   -   a payment detector for detecting whether a payment has been         received;     -   a user input device and a display for allowing a user to select         parameters within a bank of parameters when a payment is         received;     -   an image acquisition system for capturing at least two images of         a subject in view of the parameters selected by the user;     -   a first calculator for calculating a 3D image with said at least         two images captured;     -   a second calculator for extracting a set of 3D data from the 3D         image;     -   a manufacturing device for producing the personalized 3D object         in view of the set of 3D data and the parameters selected by the         user; and     -   an exit for delivering the personalized 3D object to the user.

Embodiments of the invention will be described with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective front view of a photo kiosk according to one embodiment of the present invention.

FIG. 2 is a perspective rear view of the photo kiosk shown in FIG. 1.

FIG. 3 is a perspective left side view of internal parts of the main enclosure of the photo kiosk shown in FIGS. 1 and 2.

FIG. 4 is a perspective right side view of internal parts of the main enclosure of FIGS. 1 to 3.

FIG. 5 is a partial rear and right side perspective view of internal parts of the main enclosure shown in FIGS. 1 to 4.

FIG. 6 is a partial front perspective view of internal parts of the main enclosure shown in FIGS. 1 to 5.

FIG. 7 is a perspective view of internal parts of the main enclosure shown in FIGS. 1 to 6.

FIG. 8 is a perspective view of internal parts of the main enclosure shown in FIGS. 1 to 6.

FIG. 9 shows a flow chart illustrating steps of a method for producing a personalized 3D object according to one embodiment of the present invention.

FIG. 10 shows a detailed flow chart illustrating steps of a method according to one embodiment of the present invention.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS

Referring now to FIGS. 1 to 8 there is shown an apparatus 10 according to one embodiment of the invention. In one embodiment, the apparatus is a kiosk including an optical 3D imaging device where a user can have his face, bust, or any other object captured in a 3D digital form with a color overlay. After some processing, the 3D images representing the subject can be engraved by a sub-surface laser engraver 90 within a crystal.

The apparatus 10 comprises a payment detector 16 for detecting whether a payment has been received and a user input device 20 and a display 18 for allowing a user to select parameters within a bank of parameters when a payment is received. The apparatus also comprises an image acquisition system 50 for capturing at least two images of a subject in view of the parameters selected by the user. In one embodiment, the image acquisition system 50 has a projector for projecting a pattern unto the subject and a camera 60 to acquire four images. In one embodiment, the projector and the camera 60 are set up in such a way as to offer an extended non-ambiguity zone. The apparatus 10 also comprises a calculator 80 for calculating a 3D image with the at least two images captured and a calculator 80 for extracting a set of 3D data from the 3D image.

The apparatus 10 also comprises a manufacturing device for producing the personalized 3D object in view of the set of 3D data and the parameters selected by the user and an exit 106 for delivering the personalized 3D object to the user. In one embodiment, the manufacturing device comprises a platform 94, a loading device 98 for loading a blank 3D object onto the platform, an altering device for altering the blank 3D object in view of the set of 3D data and the parameters selected by the user, and to produce the personalized 3D object. In one embodiment, the blank 3D object is made of optical glass, and the altering device is a sub surface laser engraver 90. In another embodiment, the manufacturing device comprises a delivering device 104 for delivering the personalized 3D object to the user via the exit 106.

In one embodiment, the apparatus 10 also comprises a panel of a uniform color facing the image acquisition system 54.

Now referring to FIGS. 1, 3 and 4 the apparatus 10 is a photo kiosk similar to a standard photo vending machine, but its shape may vary. In one embodiment, there is a front door 26 with a door handle 28 which gives access to the components inside the main enclosure 12 of the kiosk. The kiosk comprises a display 18 connected to the main computer 80. This display 18 may be used to show all the instructions and controls intended for human interaction done by the user but could also show various other materials that could be used for the self-promotion of the kiosk or its derived products. In one embodiment, the display 18 is a flat Liquid Crystal Display (LCD) touch screen monitor and thus it is also the user input device 20. In another embodiment, the user input device 20 could be a keyboard or a remote control with mechanical buttons or any other kind of input device. The computer 80 controls all the main components of the kiosk and is provided with a network or internet connection, either wireless or cable, to transfer the acquired 3D data to a server for later purposes. The kiosk can also be provided with a secondary display 30 connected to the computer 80, and positioned outside the kiosk for marketing purposes.

In one embodiment, the kiosk comprises a window 24 behind which is positioned the image acquisition system 50. It also comprises a payment detector 16 linked to a computer 80, preferably but not necessarily the main computer 80, for managing information pertaining to credit information. The exact nature, position, shape and capabilities of the payment detector 16 are expected to change depending on marketing approaches, physical layout and design of the kiosk, or physical location of the kiosk. The kiosk comprises an exit 106 where the crystal cube is delivered once engraved.

Additional illumination 32 can also be present, but is not mandatory, on each side of the window 50. The back side of the kiosk preferably comprises a secondary display 30, which is preferably a flat LCD monitor, for marketing purposes.

Now referring to FIGS. 2 to 4, there is an optional cooling vent 40 part of a cooling system that might be required to eliminate heat produced by the laser 90. In one embodiment, the kiosk offers a bench 22 where the subject is expected to sit or be deposited. The bench 22 is positioned at the proper distance, within the extended non-ambiguity zone, from the image acquisition system 50, for optimal quality of the 3D images. This distance is expected to change if the internal configuration of the image acquisition system 50 changes. If a bench 22 is present in the kiosk, the space under it can be used for storage of a computer 80, whether the one controlling the main components of the kiosk, the main computer 80, or any other necessary computer. Otherwise, this space could be used for general storage purposes. In one embodiment, a panel 54 made of a uniform color is part of the kiosk, for example, blue color. The panel 54 can be made of cloth, plastic or any other materials, and may be used for background recognition by the 3D background extraction algorithms.

Now referring to FIGS. 1 and 3 to 7, the main enclosure 12 comprises an image acquisition system 50 and a cooling system comprising a fan 44, a water reservoir 46 and a pump 42. In one embodiment, a manufacturing device is also present in the main enclosure and comprises cube storage 102 to insure the proper storage of all the cube formats that are offered for engraving, a platform 94, a loading and unloading device 98 for loading, unloading and positioning the crystal cubes onto the platform 94 near the laser for the engraving, the platform sliding up and down as the cube is being engraved, a drop chute 104 and motors for cube displacement 100 for delivering the cubes in the exit 106 outside the kiosk. The manufacturing device may further comprise a laser 90 and laser optical components 92, as required for sub-surface engraving. These components should not be limiting and the exact shape, size, number, layouts, functionalities and positions will depend on the kiosk layout, the types of cubes being engraved, the power required by the laser, or other factors. In one embodiment, the manufacturing device is designed to handle a small number of only one type of cube. It is understood that this manufacturing device cannot be limited to this particular design and that designs able to manipulate many different forms and sizes of cubes could be used.

Now referring to FIGS. 1, 4 and 8, there is a possible design for the single order image acquisition system 50 with an extended non-ambiguity zone that may be installed in the kiosk. This image acquisition system 50, controlled by the main computer 80, could be, in another embodiment, either fixed or attached to some sort of positioning device, depending on the exact layout of the kiosk. In one embodiment, the image acquisition system 50 is fixed mount but this configuration may not be used as a limiting factor for the exact shape, size, connections, or functionalities of the chosen image acquisition system 50 which could vary. In one embodiment, the image acquisition system 50 is capable of taking the necessary images required to extract a 3D model, with color overlay, and this extraction is advantageously doable without human interaction. An example of some of the components that make up such an image acquisition system 50 comprises a projection system based on the projection of a moire pattern on the subject, a shutter system 62, a camera 60 for the acquisition of the color images, lenses 70, a motor 68 and a slide support 66, wherein all may be attached to a single main support 72. Other types of 3D acquisition systems could be based on stereovision or any other 3D acquisition technique known in the art.

Now referring to FIGS. 1, 3, 4, 8 and 9, software, installed on the main computer 80, performs some, all, or more, among the following instructions: controlling the image acquisition system 50, extracting the 3D data, controlling the manufacturing device and its many components for the cube positioning and delivery, controlling the laser 90 for the engraving process and controlling the displays 18, 30, the user input device 20, the payment detector 16, the additional illumination 32 and the cooling system.

In one embodiment, the main computer 80 is connected to an outside server and additional computers might also be used if necessary. The network connection can be achieved either through wireless or cable connections, the choice being dependent on what is available at the location where the kiosk is installed.

The server connected to the kiosk can be used, among other things, for storage of the 3D model data and color overlay. Additional information could also be stored, as deemed necessary, such as the 3D points cloud used for the original crystal cube engraving.

Referring now to FIGS. 1 to 10, a user wanting a personalized 3D object enters the kiosk. The user may want, as a subject, his face or bust digitized in 3D for obtaining his virtual 3D model engraved in a crystal which is in fact optical glass, or he may want to digitize another object or part of a living being. Upon entering the kiosk, the user is invited to make a payment and if a payment is received, he is invited to select different parameters and options for the 3D capture and the crystal-engraving, by means of a user input device 20 and a display 18. In one embodiment, the user input device 20 and the display 18 are comprised in the same apparatus which is preferably a flat LCD touch screen monitor. Among the parameters and options, but not limited to these, are: the type of crystal desired, for example a cube, a necklace, a key chain, etc.; and the orientation for the laser engraving, for example landscape or portrait, this nomenclature being used in the same context as with regular 2D still photographs.

According to one embodiment, once the user is ready for the 3D capture, a visual signal is emitted indicating the launch of the 3D image acquisition. The image acquisition system 50 is a non-contact color digitizer, based on the projection of more patterns onto the subject. The digitized has an extended non-ambiguity zone, covering a calibrated volume that extends to the panel 54 at the rear and to a distance at the front somewhere between the bench and the window 24.The exposure time of the camera 60 of the image acquisition system 50 is adjusted by turning on the projector and by illuminating the subject for a small amount of time. The live video of the subject is then projected on the display 18, so the position of the subject can be adjusted. The image acquisition system 50 captures four images, in view of the parameters and options previously selected. Each 3D capture takes a fraction of second and the 3D image is obtained through calculation techniques well documented and known in the art. The extraction of a set of 3D data from the 3D image is carried out by software running on the main computer 80. The following operations are done to the 3D image in order to obtain a 3D points cloud. It should be understood that the format of the data should not be limited to a point cloud, but include any kind of 3D data representation.

In one embodiment, the method includes the steps of: localizing the background of the 3D image thanks to the panel of a uniform color placed behind the subject; clipping the background to produce a foreground 3D image; and applying a cropping shape, that may be selected by the user or automatically, to the foreground 3D image presented on the display as a texture mapped 3D model to produce a cropped 3D image. The method further comprises the step of producing a set of 3D data from the cropped 3D image, consisting of a 3D points cloud which is laser engravable. The 3D points cloud could be replaced by any mode of representation of data in 3D, which is readable by the selected manufacturing device.

In one embodiment, the set of 3D data is then used to compute a 3D image of the personalized 3D object. The user is then given the choice of either starting the production of the personalized 3D object, as shown on the display 18, or making another 3D capture. The number of three 3D captures may be limited. After the limit is reached the user is invited to select one of the proposed 3D images for producing the personalized 3D object.

Once the user has selected the set of 3D data to be used, the production of the personalized 3D object, in view of the parameters and options selected, can begin. Software running on the main computer 80 controls the hardware equipment necessary to produce the personalized 3D object. First, a loading and unloading device 98 loads a crystal onto an engraving platform 94. The set of 3D data are fed to the laser 90 which starts fabricating the personalized 3D object in view of the set of 3D data and the parameters and options selected by the user. The laser engraver 90 then starts the engraving process in the crystal cube. The computer 80, combined with the software, controls the laser engraver, which in turn, burns the points in different 3D locations inside the crystal cube. The arrangement of these points, within the cube, is what defines the image or portrait. When the engraving is done, the loading and unloading device 98 pushes the personalized 3D object further into a drop chute 104 which leads to the exit 106 thus delivering the personalized 3D object to the user. In addition, a receipt may be delivered to the user, the receipt comprising a website address, a randomly created password and a set of instructions for ordering additional products. The delivering device, including a drop chute 104 and an exit 106 in one embodiment, is designed in such a way that the engraved crystal and additional items, if appropriate, can be easily picked up. Other types of delivery mechanisms could be envisioned, for instance, a separate printer could print the receipt at the same time as the cube is being delivered.

In addition to the production of a personalized 3D object, the raw 3D images and the set of 3D data used for producing the personalized 3D object are transferred to a server via a network connection or stored temporarily on the computer in the absence of a sufficiently fast network connection. By visiting the website address printed onto the receipt and by using the password also printed onto the receipt, the user is able to access his data. The data is kept on the server for a predetermined number of days, may be specified on the receipt. The data can be accessed for many purposes such as ordering customized products or downloading the data for personal use. A number of additional personalized products can be ordered from the website and the texture mapped 3D model can be used, with some additional generic or personal information (2D or 3D) added by the user through the website, for the production of actual or virtual goods such as other crystal engraved items, busts or other shapes printed through some type of 3D printing device, monochrome or color, that could be using gels, starch or other materials, lenticular prints, personalized dolls, bobble head dolls, stereoscopic photos, animated screen savers, 3D Stereo Portraits™, CAD/CAM busts, tombstones, decorative ornaments, plaques, jewelry, popular 3D files, avatars or personalized characters for videogames or for use in computer animations or for artistic purposes, etc.

The kiosk also has a self-promotion concept. An outside display 30 is used to either display a video sequence in a loop, showing a generic 3D image acquisition and sub-surface laser engraving process, or to display the 3D acquisition session currently under way. Also, during the different laps of time where the user is waiting upon data calculation or upon the engraving process to finish, the software can display promotional material on the display 18 located inside the kiosk. Among the tasks performed by the software, there is also having feedback mechanisms that could warn users and technicians of technical problems that could be encountered.

Mass consumption items could be made available for the user through the web site. The mass consumption item production process born from the 3D data collection process relates to all types of customizable products that can be produced thanks to the collected 3D data of each user. This new method consists in manufacturing the body part using rapid prototyping machines and then physically attaching/merging it to a prefabricated customizable/mass consumption item. This invention encompasses all types of rapid prototyping technology and all available material capable of producing the results. These customizable/mass consumption products can be either hard physical and tangible objects or soft objects such as virtual data. The mass fabricated items, before being customized, are “blanks”, i.e., without customized option. These “blanks”, for example bobble head dolls, can be mass-produced. To achieve production of a customized mass consumption item, one may need to physically manufacture the object thanks to the data obtained from the data collection step. The scanned 3D body parts can be produced by rapid prototyping technologies, like CNC milling machines. A CNC milling machine can literally carve the 3D body part out of a wide array of material like wax, wood, marble, Styrofoam® etc. Certain 3D printers can even produce the part in full color, which was impossible until recent advancements in that technology. If this technology is not available, the part can always be painted afterwards. The 3D objects such as customized heads can then be attached to the mass fabricated item. The subject's 3D face data is printed in 3D and then attached to a customizable mass consumption item, for example, a bobble head doll. The mass consumption item that was once generic is now customized. The item is thusly, endowed with the subjects “personality” and becomes a very attractive consumable item.

One embodiment of this invention is advantageous because the method and apparatus for creating the personalized 3D object can be done without human intervention other than the users.

It goes without saying that numerous modifications could be made to embodiments of the invention which have just been described, without departing from the scope of this invention such as defined in the annexed claims. Thus, for example, in the embodiments, references have been made to photo kiosk, main enclosure, payment detector, display, user input device, bench, window, front door, door handle, secondary display, additional illumination, cooling vent, pump, fan, water reservoir, image acquisition system, panel of a uniform color, camera, shutter system, lamp, slide support, motor, lens, main support, main computer, secondary computer, server, network connection, laser, laser optical components, movable cube support, loading/unloading device, platform, motors for cube displacement, cube storage, drop chute, exit, etc. It has to be understood that the structures and geometrical configurations of the components described hereinabove are not essential to the invention and should not be taken in a restrictive way to limit the scope of this invention. It would actually be obvious for any person of the art that other components, other types of cooperation between the components as well as other geometrical configurations could be used. 

1. A method for producing a personalized 3D object, comprising: detecting whether a payment has been received, and if a payment is received: i) inviting a user to select parameters within a bank of parameters by means of a user input device and a display; ii) capturing at least two images of a subject in view of the parameters selected in i); iii) calculating a 3D image with said at least two images captured in ii); iv) extracting a set of 3D data from the 3D image; v) producing the personalized 3D object in view of the set of 3D data extracted in iv) and the parameters selected in i); and vi) delivering the personalized 3D object to the user.
 2. The method according to claim 1, further comprising: performing at least two iterations of ii), iii) and iv) before v) to obtain additional sets of 3D data; displaying to the user proposed 3D images corresponding to the sets of 3D data; and inviting the user to select one of the proposed 3D images; wherein, in v), the personalized 3D object is produced in view of the set of 3D data corresponding to the 3D image selected by the user.
 3. The method according to claim 1, wherein iv) comprises localizing a background in the 3D image; clipping the background to produce a foreground 3D image; applying a predetermined cropping shape to the foreground 3D image to produce a cropped 3D image; and producing a set of 3D data, consisting of a 3D points cloud, from the cropped 3D image.
 4. A method according to claim 1, wherein v) comprises: loading a blank 3D object onto a platform; and altering the blank 3D object with an altering device in view of the 3D data and the parameters selected by the user, to produce the personalized 3D object.
 5. A method according to claim 4, wherein the blank 3D object is made of optical glass.
 6. A method according to claim 4, wherein the altering device is a sub surface laser engraver.
 7. A method according to claim 1, further comprising, after vi): delivering a receipt to the user comprising a web site address, a password and a set of instructions for ordering additional products; and transferring the set of 3D data to a server via a network connection.
 8. A method according to claim 1, further comprising calibrating the image acquisition system at predetermined time intervals.
 9. An apparatus for producing a personalized 3D object, comprising a payment detector for detecting whether a payment has been received; a user input device and a display for allowing a user to select parameters within a bank of parameters when a payment is received; an image acquisition system for capturing at least two images of a subject in view of the parameters selected by the user; a first calculator for calculating a 3D image with said at least two images captured; a second calculator for extracting a set of 3D data from the 3D image; a manufacturing device for producing the personalized 3D object in view of the set of 3D data and the parameters selected by the user; and p1 an exit for delivering the personalized 3D object to the user.
 10. An apparatus according to claim 9, wherein the manufacturing device comprises a platform; a loading device for loading a blank 3D object onto the platform; an altering device for altering the blank 3D object in view of the set of 3D data and the parameters selected by the user, and to produce the personalized 3D object; and a delivering device for delivering the personalized 3D object to the user via the exit.
 11. An apparatus according to claim 10, wherein the blank 3D object is made of optical glass.
 12. An apparatus according to claim 10, wherein the altering device is a sub surface laser engraver.
 13. An apparatus according to claim 9, wherein the image acquisition system has a projector for projecting a pattern unto the subject and a camera to acquire said at least two images, and said at least two images comprise four images.
 14. An apparatus according to claim 13, wherein the projector and the camera are set up in such a way as to offer an extended non-ambiguity zone.
 15. An apparatus according to claim 14, further comprising a panel of a uniform color facing the image acquisition system. 